Apparatus and method for manufacturing an automotive beam

Abstract

In an apparatus and method for manufacturing an automotive beam for use as a beam in structural components of automobiles, the beam is provided with significant improvements in terms of torsional rigidity and yield strength. The beam improves the overall safety of passengers and maintains the simplicity of the manufacturing process. The apparatus ( 1 ) for manufacturing roll formed profile beams comprises a plurality of material dispensers ( 2,6 ), a first set of rollers ( 5 ), a second set of rollers ( 11 ), a first welding station ( 10 ) mounted between the two sets of rollers ( 5, 11 ) and a second welding station ( 12 ) at the outlet of the second set of rollers ( 11 ). The method of manufacturing roll formed profile beams comprises the steps of roll forming a first profile element followed by roll forming a second profile element enclosing the first profile element and forming a closed profile beam having an internal support structure.

The invention claimed is: 
     
       1. An apparatus for manufacturing roll formed profile beams comprising:
 (a) a first material dispenser for dispensing a first material; 
 (b) a first set of rollers having an inlet in communication with the first material dispenser to receive the first material being dispensed therefrom, the first set of rollers being adapted to form the first material into a first profile element having a predefined cross-sectional profile; 
 (c) a second material dispenser for dispensing a second material adjacent the first material at an outlet of the first set of rollers; 
 (d) a first welding station for welding the first material to the second material adjacent thereto; 
 (e) a second set of rollers for receiving the welded first and second materials from the first welding station, the second set of rollers being adapted to form the second material into a second profile element having a predefined cross-sectional profile which encloses the first profile element; and 
 (f) a second welding station in communication with an outlet of the second set of rollers for welding portions of the second material together as the welded first and second materials exit from the outlet of the second set of rollers to form a closed profile beam. 
 
     
     
       2. An apparatus as claimed in  claim 1 , wherein the first material dispenser is provided by an uncoiler and the first material is a coil of sheet material carried by the first material dispenser. 
     
     
       3. An apparatus as claimed in  claim 2 , wherein the second material dispenser is provided by an uncoiler and the second material is a coil of sheet material carried by the second material dispenser. 
     
     
       4. An apparatus as claimed in  claim 1 , wherein the second material dispenser is provided by an uncoiler and the second material is a coil of sheet material carried by the second material dispenser. 
     
     
       5. An apparatus as claimed in  claim 1 , wherein the first and second materials are sheet materials. 
     
     
       6. An apparatus as claimed in  claim 5 , wherein the sheet materials are high strength steel. 
     
     
       7. An apparatus as claimed in  claim 6 , wherein the steel is boron steel. 
     
     
       8. An apparatus as claimed in  claim 6 , wherein the first and second materials are made from the same steel. 
     
     
       9. An apparatus as claimed in  claim 6 , wherein the first and second materials are manufactured from different steels. 
     
     
       10. An apparatus as claimed in  claim 5 , wherein the sheet materials have the same thickness. 
     
     
       11. An apparatus as claimed in  claim 5 , wherein the sheet material has different thicknesses. 
     
     
       12. An apparatus as claimed in  claim 5 , wherein at least one of the sheet materials defines pre-punched apertures at predetermined locations. 
     
     
       13. An apparatus as claimed in  claim 5 , wherein the sheet materials define pre-punched apertures at predetermined locations. 
     
     
       14. A method of manufacturing roll formed profile beams comprising the steps of: roll forming a first sheet material travelling in a path into a first profile element having a predefined cross-sectional profile followed by roll forming a second sheet material travelling in a path into a second profile element having a predefined cross-sectional profile which encloses the first profile element to form a closed profile beam. 
     
     
       15. A method as claimed in  claim 14 , wherein the first profile element is formed as an internal support profile. 
     
     
       16. A method as claimed in  claim 14 , wherein the first profile element is a substantially U-shaped profile. 
     
     
       17. A method as claimed in  claim 16 , wherein legs of the substantially U-shaped profile element include ribs. 
     
     
       18. A method as claimed in  claim 14 , wherein, during roll forming of the second profile element, a second sheet is roll formed into the second profile element enclosing the first profile element. 
     
     
       19. A method as claimed in  claim 18 , wherein, prior to the roll forming of the second profile element, the first profile element is welded to the second sheet at a welding station. 
     
     
       20. A method as claimed in  claim 19 , wherein the first profile element is welded to the second sheet by means of seam welding. 
     
     
       21. A method as claimed in  claim 14 , further comprising the step of welding longitudinal edges of the second profile element together with a portion of the first profile element thereby enclosing the first profile element within the second profile element. 
     
     
       22. A method as claimed in  claim 21 , wherein the longitudinal edges of the second profile element are laser welded together with the portion of the first profile element.